Slurry Treatment Method and Apparatus

ABSTRACT

A method of extracting bitumen from tar sands includes providing an apparatus for mixing fluids, the apparatus including: a housing, a substantially cylindrical rotor rotatably mounted within the interior chamber, a first array of spaced bores formed in the peripheral surface of the rotor, a second array of spaced bores formed in the peripheral surface of the rotor, a first fluid inlet in the housing, a second fluid inlet in the housing, and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber to minimize cavitation damage at the location of the fluid outlet, and providing a separation composition at the second predetermined location, the separation composition including: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH greater than 7.5.

FIELD OF THE INVENTION

The present invention relates to extraction of bitumen from tar sands.

BACKGROUND OF THE INVENTION

Oil sands, also known as “tar sands” and “bituminous sands,” are a mixture of bitumen (tar), sand, and water. Bitumen is a heavy, viscous crude oil, having relatively high sulfur content. When properly separated from the oil sands, bitumen may be processed to synthetic crude oil suitable for use as a feedstock for the production of liquid motor fuels, heating oil, and petrochemicals. Oil sand fields exist throughout most of the world. Particularly significant deposits exist in Canada, including the Athabasca oil sands in Alberta, the United States, including the Utah oil sands, South America, including the Orinoco oil sands in Venezuela, and Africa, including the Nigerian oil sands. A majority of all of the known oil in the world is contained in oil sands.

Bitumen can be derived from a slurry containing tar sands using high shear mixing equipment. The tar sands are highly abrasive on the machinery used to separate the bitumen from the sand and water. Conventional mixing equipment is subject to high wear rates that result from high speed operation on the abrasive tar sand slurry. Slower speed equipment is less effective at bitumen derivation.

The impellers used in the high-speed mixing equipment may have a useful life of only a few of hours before needing to be replaced. Naturally, this requires frequent downtime for the machinery, which means the equipment is rendered unusable and valuable work time is lost due to frequent repairs. Using less abrasion-prone materials, such as ceramics, for the impellers has been proposed in the past, but has not adequately relieved the problem of extending the usable life of the mixing equipment.

Accordingly, there is a need and desire to provide a method and apparatus for deriving bitumen from tar sand slurry that has an extended usable lifetime.

SUMMARY OF THE INVENTION

Embodiments of the present invention advantageously provide a method of extracting bitumen from tar sands that has an extended usable lifetime. An embodiment of the invention includes a method of extracting bitumen from tar sands, the method comprising providing an apparatus for mixing fluids, the apparatus comprising: a housing defining a substantially cylindrical interior chamber bounded by spaced substantially planar side walls joined by a cylindrical peripheral wall; a substantially cylindrical rotor rotatably mounted within the interior chamber, the rotor having an axis, spaced substantially planar sides, and a cylindrical peripheral surface joining the planar sides; the cylindrical peripheral surface of the rotor and the cylindrical peripheral wall of the chamber defining an annular space therebetween having a substantially uniform dimension in the axial direction of the rotor; at least two arrays of spaced bores formed in the peripheral surface of the rotor, each bore of each array extending radially into the rotor a predetermined distance and opening into the annular space, the each array of spaced bores being arranged in a row that extends around the cylindrical peripheral surface of the rotor and being spaced from other arrays such that a void zone therebetween is created where no bores are formed in the peripheral surface of the rotor; at least one fluid inlet in the housing positioned to introduce fluid into the chamber at predetermined locations adjacent one of the substantially planar sides of the rotor; multiple inlets being substantially aligned to equalize pressure on the rotor as fluid is introduced into the chamber through the fluid inlets; and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber at a third predetermined location adjacent the cylindrical peripheral surface of the rotor, the third predetermined location being aligned within the void zone for withdrawal of fluid after it has passed a row of bores and to minimize cavitation damage at the location of the fluid outlet; and providing a separation composition comprising: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition; a hydrotropic agent; and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.

Another embodiment of the invention includes an apparatus for extracting bitumen from tar sands, the apparatus including: a housing defining a substantially cylindrical interior chamber bounded by spaced substantially planar side walls joined by a cylindrical peripheral wall; a substantially cylindrical rotor rotatably mounted within the interior chamber, the rotor having an axis, spaced substantially planar sides, and a cylindrical peripheral surface joining the planar sides; the cylindrical peripheral surface of the rotor and the cylindrical peripheral wall of the chamber defining an annular space therebetween having a substantially uniform dimension in the axial direction of the rotor; a first array of spaced bores formed in the peripheral surface of the rotor, each bore of the first array extending radially into the rotor a predetermined distance and opening into the annular space, the first array of spaced bores being arranged in a first row that extends around the cylindrical peripheral surface of the rotor; a second array of spaced bores formed in the peripheral surface of the rotor, each bore of the second array extending radially into the rotor a predetermined distance and opening into the annular space, the second array of spaced bores being arranged in a second row that extends around the cylindrical peripheral surface of the rotor, the first and second rows of bores being spaced apart in the axial direction of the rotor and defining a void zone therebetween such that no bores are formed in the peripheral surface of the rotor; a first fluid inlet in the housing positioned to introduce fluid into the chamber at a first predetermined location adjacent one of the substantially planar sides of the rotor; a second fluid inlet in the housing positioned to introduce fluid into the chamber at a second predetermined location adjacent the other one of the substantially planar sides of the rotor, the second fluid inlet being substantially axially aligned with the first fluid inlet to equalize pressure on the rotor as fluid is introduced into the chamber through the fluid inlets; and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber at a third predetermined location adjacent the cylindrical peripheral surface of the rotor, the third predetermined location being aligned within the void zone for withdrawal of fluid after it has passed a row of bores and to minimize cavitation damage at the location of the fluid outlet, wherein the apparatus is configured to receive a separation composition comprising: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition; a hydrotropic agent; and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of various embodiments of the disclosure taken in conjunction with the accompanying figures, wherein:

FIG. 1 is a partially sectioned view illustrating an embodiment of an apparatus for mixing fluids, for example, a slurry (Bitumen/sand/water-chemistry).

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof and show by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized, and that structural, logical, processing, and electrical changes may be made. It should be appreciated that any list of materials or arrangements of elements is for example purposes only and is by no means intended to be exhaustive. The progression of processing steps described is an example; however, the sequence of steps is not limited to that set forth herein and may be changed as is known in the art, with the exception of steps necessarily occurring in a certain order.

As used herein, the term “about” means “approximately,” and may indicate as much as a 10% deviation from the number being modified. As used herein, “essentially free” means an amount less than about 0.1%.

The invention will now be described with reference to the drawing figures in which like reference numerals refer to like parts throughout. Embodiments of the invention include bitumen-removal machinery combined with organic chemistry to remove the bitumen from tar sands while reducing wear on the equipment.

As depicted in FIG. 1, a hydrosonic mixer 11 comprises a cylindrical housing 12 defining an internal cylindrical chamber 15. In the illustrated embodiment, the housing 12 is formed by a casing 13 capped by an end plate 14 secured to the casing with bolts 16. The housing 12 may be formed in other ways such as, for example, a central cylindrical shell capped by two end plates.

A cylindrical rotor 17 is disposed within the cylindrical chamber 15 of the housing and is mounted on an axially extending shaft 18. The shaft 18 is supported on either side of the rotor 17 within bearing assemblies 19 that, in turn, are mounted within bearing assembly housings 21. The bearing assembly housings 21 are secured to the housing 12 by means of appropriate fasteners such as bolts 22. The shaft 18 projects from one of the bearing housings 21 for being coupled to a motive means such as an electric motor (not shown). It will thus be seen that the rotor 17 may be spun or rotated within the cylindrical chamber 15 in the direction of arrows 23 by activating the motor coupled to the shaft 18.

The rotor 17 has a peripheral surface that is formed with one or more circumferentially extending arrays of irregularities in the form of relatively shallow holes or bores 24. Embodiments may include a rotor 17 that is provided with two arrays of bores 24 separated by a void 26, the purpose of which is described in more detail below. It should be understood, however, that fewer or more than two arrays of bores may be provided in the peripheral surface of the rotor as desired depending upon the intended application of the hydrosonic mixer 11. Further, irregularities other than holes or bores also may be provided. The rotor 17 is sized relative to the cylindrical chamber 15 in which it is housed to define a space, referred to herein as a cavitation zone 32, between the peripheral surface of the rotor and the cylindrical wall of the chamber 15.

Inlet ports 25 are provided in the housing 12 for supplying fluids to be mixed to the interior chamber 15 within the housing. Supply conduits 30 are coupled to the inlet ports 25. A liquid supply conduit 27 is coupled to the supply conduits 30 for supplying liquid such as Bitumen slurry to the hydrosonic mixer 11. A supply conduit 28 communicates with the liquid supply conduit 27 for introducing and entraining additives/make up chemistry within the stream of liquid flowing through the liquid supply conduit 27.

The mixer 11 will likely not effectively separate the Bitumen from the sand components without an appropriate tar sand slurry being used. Embodiments may include a composition comprising a separating composition comprising a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition, a hydrotropic agent, and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5%.

Suitable wetting agents may include, for example, one or more of DYNOL™ 607 Surfactant (Air Products and Chemicals, Inc.), SURFYNOL® 420 (Air Products and Chemicals, Inc.), SURFYNOL® 440 (Air Products and Chemicals, Inc.), SURFYNOL® 465 (Air Products and Chemicals, Inc.), SURFYNOL® 485 (Air Products and Chemicals, Inc.), DYNOL™ 604 Surfactant (Air Products and Chemicals, Inc.), TOMADOL® 91-2.5 (Tomah Products, Inc.), TOMADOL® 91-6 (Tomah Products, Inc.), TOMADOL® 91-8 (Tomah Products, Inc.), TOMADOL® 1-3 (Tomah Products, Inc.), TOMADOL® 1-5 (Tomah Products, Inc.), TOMADOL® 1-7 (Tomah Products, Inc.), TOMADOL® 1-73B (Tomah Products, Inc.), TOMADOL® 1-9 (Tomah Products, Inc.), TOMADOL® 23-1 (Tomah Products, Inc.), TOMADOL® 23-3 (Tomah Products, Inc.), TOMADOL® 23-5 (Tomah Products, Inc.), TOMADOL® 23-6.5 (Tomah Products, Inc.), TOMADOL® 25-3 (Tomah Products, Inc.), TOMADOL® 25-7 (Tomah Products, Inc.), TOMADOL® 25-9 (Tomah Products, Inc.), TOMADOL® 25-12 (Tomah Products, Inc.), TOMADOL® 45-7 (Tomah Products, Inc.), TOMADOL® 45-13 (Tomah Products, Inc.), TRITON™ X-207 Surfactant (Dow Chemical Company), TRITON™ CA Surfactant (Dow Chemical Company), NOVEC™ Fluorosurfactant FC-4434 (3M Company), POLYFOX™ AT-1118B (Omnova Solutions, Inc.), ZONYL® 210 (Dupont), ZONYL® 225 (Dupont), ZONYL® 321 (Dupont), ZONYL® 8740 (Dupont), ZONYL® 8834L (Dupont), ZONYL® 8857A (Dupont), ZONYL® 8952 (Dupont), ZONYL® 9027 (Dupont), ZONYL® 9338 (Dupont), ZONYL® 9360 (Dupont), ZONYL® 9361 (Dupont), ZONYL® 9582 (Dupont), ZONYL® 9671 (Dupont), ZONYL® FS-300 (Dupont), ZONYL® FS-500 (Dupont), ZONYL® FS-610 (Dupont), ZONYL® 1033D (Dupont), ZONYL® FSE (DuPont), ZONYL® FSK (DuPont), ZONYL® FSH (DuPont), ZONYL® FSJ (DuPont), ZONYL® FSA (DuPont), ZONYL® FSN-100 (DuPont), LUTENSOL™ OP 30-70% (BASF), LUTENSOL® A 12 N (BASF), LUTENSOL® A 3 N (BASF), LUTENSOL® A 65 N (BASF), LUTENSOL® A 9 N (BASF), LUTENSOL® AO 3 (BASF), LUTENSOL® AO 4 (BASF), LUTENSOL® AO 8 (BASF), LUTENSOL® AT 25 (BASF), LUTENSOL® AT 55 PRILL SURFACTANT (BASF), LIJTENSOL® CF 10 90 SURFACTANT (BASF), LUTENSOL® DNP 10 (BASF), LUTENSOL® NP 4 (BASF), LUTENSOL® NP 10 (BASF), LUTENSOL® NP-100 PASTILLE (BASF), LUTENSOL® NP-6 (BASF), LUTENSOL® NP-70-70% (BASF), LUTENSOL® NP-50 (BASF), LUTENSOL® NP 9 (BASF), LUTENSOL® ON 40 SURFACTANT (BASF), LUTENSOL® ON 60 (BASF), LUTENSOL® OP-10 (BASF), LUTENSOL® TDA 10 SURFACTANT (BASF), LTJTLNSOL® TDA 3 SURFACTANT (BASF), LUTENSOL® TDA 6 SURFACTANT (BASF), LUTENSOL® TDA 9 SURFACTANT (BASF), LUTENSOL® XL 69 (BASF), LUTENSOL® XL 100 (BASF), LUTENSOL® XL 140 (BASF), LUTENSOL® XL 40 (BASF), LUTENSOL® XL 50 (BASF), LUTENSOL® XL 60 (BASF), LUTENSOL® XL 70 (BASF), LUTENSOL® XL 79 (BASF), LUTENSOL® XL 80 (BASF), LUTENSOL® XL 89 (BASF), LUTENSOL® XL 90 (BASF), LUTENSOL® XL 99 (BASF), LUTENSOL® XP 100 (BASF), LUTENSOL® XP 140 (BASF), LUTENSOL® XP 30 (BASF), LUTENSOL® XP 40 (BASF), LUTENSOL® XP 50 (BASF), LUTENSOL® XP 60 (BASF), LUTENSOL® XP 69 (BASF), LUTENSOL® XP 70 (BASF), LUTENSOL® XP 79 (BASF), LUTENSOL® XP 80 (BASF), LUTENSOL® XP 89 (BASF), LUTENSOL® XP 90 (BASF), LUTENSOL® XP 99 (BASF), MACOL® 16 SURFACTANT (BASF), MACOL® CSA 20 POLYETHER (BASF), MACOL® LA 12 SURFACTANT (BASF), MACOL® LA 4 SURFACTANT (BASF), MACOL® LF 110 SURFACTANT (BASF), MACOL® LF 125A SURFACTANT (BASF), MAZON® 1651 SURFACTANT (BASF), MAZOX® LDA Lauramine OXIDE (BASF), PLURAFAC® AO8A Surfactant (BASF), PLURAFAC® B-26 Surfactant (BASF), PLURAFAC® B25-5 Surfactant (BASF), PLURAFAC® D25 Surfactant (BASF), PLURAFAC® LF 1200 Surfactant (BASF), PLURAFAC® LF 2210 Surfactant (BASF), PLURAFAC® LF 4030 Surfactant (BASF), PLURAFAC® LF 7000 Surfactant (BASF), PLURAFAC® RA-20 Surfactant (BASF), PLURAFAC® RA 30 Surfactant (BASF), PLURAFAC® RA 40 Surfactant (BASF), PLURAFAC® RCS 43 Surfactant (BASF), PLURAFAC® RCS 48 Surfactant (BASF), PLURAFAC® S205LF Surfactant (BASF), PLURAFAC® S305LF Surfactant (BASF), PLURAFAC® S505LF Surfactant (BASF), PLURAFAC® SL 62 Surfactant (BASF), PLURAFAC® SL 92 Surfactant (BASF), PLURAFAC® SL-22 Surfactant (BASF), PLURAFAC® SL-42 Surfactant (BASF), PLURAFAC® SLF 37 Surfactant (BASF), PLURAFAC® SLF-18 Surfactant (BASF), PLURAFAC® SLF-18B-45 Surfactant (BASF), PLURAFAC® L1220 Surfactant (BASF), PLURONIC® 10R5 SURFACTANT (BASF), PLURONIC® 17R2 (BASF), PLURONIC® 17R4 (BASF), PLURONIC® 25R2 (BASF), PLURONIC® 25R4 (BASF), PLURONIC® 31R1 (BASF), PLURONIC® F108 CAST SOLID SURFACTANT (BASF), PLURONIC® F108 NF CAST SOLID SURFACTANT (BASF), PLURONIC® F108 NF PRILL SURFACTANT (BASF), PLURONIC® F108 PASTILLE SURFACTANT (BASF), PLURONIC® F127 CAST SOLID SURFACTANT (BASF), PLURONIC® F127 NF PRILL Surfactant (BASF), PLURONIC® F127NF 500BHT CAST SOLID SURFACTANT (BASF), PLURONIC® F38 CAST SOLID SURFACTANT (BASF), PLURONIC® PASTILLE (BASF), PLURONIC® F68 LF PASTILLE SURFACTANT (BASF), PLURONIC® F68 CAST SOLID SURFACTANT (BASF), PLURONIC® F77 CAST SOLID SURFACTANT (BASF), PLURONIC® F-77 MICRO PASTILLE SURFACTANT (BASF), PLURONIC® F87 CAST SOLID SURFACTANT (BASF), PLURONIC® F88 CAST SOLID SURFACTANT (BASF), PLURONIC® F98 CAST SOLID SURFACTANT (BASF), PLURONIC® L10 SURFACTANT (BASF), PLURONIC® L101 SURFACTANT (BASF), PLURONIC® L121 SURFACTANT (BASF), PLURONIC® L31 SURFACTANT (BASF), PLURONIC® L92 SURFACTANT (BASF), PLURONIC® N-3 SURFACTANT (BASF), PLURONIC® P103 SURFACTANT (BASF), PLURONIC® P105 SURFACTANT (BASF), PLURONIC® P123 SURFACTANT (BASF), PLURONIC® P65 SURFACTANT (BASF), PLURONIC® P84 SURFACTANT (BASF), PLURONIC® P85 SURFACTANT (BASF), TETRONIC® 1107 micro-PASTILLE SURFACTANT (BASF), TETRONIC® 1107 SURFACTANT (BASF), TETRONIC® 1301 SURFACTANT (BASF), TETRONIC® 1304 SURFACTANT (BASF), TETRONIC® 1307 Surfactant (BASF), TETRONIC® 1307 SURFACTANT PASTILLE (BASF), TETRONIC® 150R1 SURFACTANT (BASF), TETRONIC® 304 SURFACTANT (BASF), TETRONIC® 701 SURFACTANT (BASF), TETRONIC® 901 SURFACTANT (BASF), TETRONIC® 904 SURFACTANT (BASF), TETRONIC® 908 CAST SOLID SURFACTANT (BASF), and TETRONIC® 908 PASTILLE SURFACTANT (BASF), and mixtures thereof.

The wetting agent may include one or more ethoxylated acetylenic alcohols, such as, for example, 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate.

Suitable hydrotropic agents may include, for example, one or more of TRITON® H-66 (Dow Chemical Company), TRITON® H-55 (Dow Chemical Company), TRITON® QS-44 (Dow Chemical Company), TRITON® XQS-20 (Dow Chemical Company), TRITON® X-15 (Union Carbide Corporation), TRITON® X-35 (Union Carbide Corporation), TRITON® X-45 (Union Carbide Corporation), TRITON® X-114 (Union Carbide Corporation), TRITON® X-100 (Union Carbide Corporation), TRITON® X-165 (70%) active (Union Carbide Corporation), TRITON® X-305 (70%) active (Union Carbide Corporation), TRITON® X-405 (70%) active (Union Carbide Corporation), TRITON® BG Nonionic Surfactant (Union Carbide Corporation), TERGITOL® MinFoam 1X (Dow Chemical Company), TERGITOL® L-61 (Dow Chemical Company), TERGITOL® L-64 (Dow Chemical Company), TERGITOL® L-81 (Dow Chemical Company), TERGITOL® L-101 (Dow Chemical Company), TERGITOL® NP-4 (Dow Chemical Company), TERGITOL NP-6 (Dow Chemical Company), TERGITOL® NP-7 (Dow Chemical Company), TERGITOL® NP-8 (Dow Chemical Company), TERGITOL® NP-9 (Dow Chemical Company), TERGITOL® NP-11 (Dow Chemical Company), TERGITOL® NP-12 (Dow Chemical Company), TERGITOL® NP-13 (Dow Chemical Company), TERGITOL® NP-15 (Dow Chemical Company), TERGITOL® NP-30 (Dow Chemical Company), TERGITOL® NP-40 (Dow Chemical Company), SURFYNOL® 420 (Air Products and Chemicals, Inc), SURFYNOL® 440 (Air Products and Chemicals, Inc.), SURFYNOL® 465 (Air Products and Chemicals, Inc.), SURFYNOL® 485 (Air Products and Chemicals, Inc.), MAPHOS® 58 ESTER (BASF), MAPHOS® 60 A Surfactant (BASF), MAPHOS® 66H ESTER (BASF), MAPHOS® 8135 ESTER (BASF), MAPHOS® M-60 ESTER (BASF), 6660 K Hydrotroping Phosphate Ester Salt (Burlington Chemical), Burofac 7580 Aromatic Phosphate Ester (Burlington Chemical), and Burofac 9125 (Burlington Chemical), and mixtures thereof. The hydrotropic agent may be one or more aromatic phosphate esters, such as, for example, an aromatic phosphate ester having the formula:

wherein R¹ is a C₁-C₅ linear or branched alkyl group and n=1 to 8, e.g., an integer between one and eight.

Suitable dispersants having flocculating characteristics may include, for example, one or more of sodium acid pyrophosphate, tetrapotassium pyrophosphate, monosodium phosphate (H₆NaO₆P), monoammonium phosphate ((NH₄)PO₄), sodium acid phosphate, trisodium phosphate, sodium tripolyphosphate, sodium trimetaphosphate, sodium laurel phosphate, sodium phosphate, pentapotassium triphosphate, potassium triphosphate, tetraborate potassium tripolyphosphate, potassium phosphate-monobasic, potassium phosphate-dibasic, monopotassium phosphate, and tripotassium phosphate, and mixtures thereof.

The dispersant having flocculating characteristics may include one or more pyrophosphate salts, including, for example, one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.

In one embodiment, the hydrotropic agent may be present in the amount of from about 0.1% to about 4.0% by weight of the separating composition. The dispersant having flocculating characteristics may be present in the amount of from about 0.25% to about 4.5% by weight of the separating composition.

In one embodiment, the separating composition may further comprise a strong base, such as, for example, hydroxides of alkali metals and alkaline earth metals, such as, for example, NaOH, KOH, Ba(OH)₂, CsOH, SrOH, Ca(OH)₂, LiON, RbOH, NaH, LDA, and NaNH₂. As used herein, a “strong base” is a chemical compound having a pH of greater than about 13. The strong base may be present in the amount of from about 2% to about 9.5% by weight of the separating composition.

The separating composition may further comprise a heavy acid, such as, for example, phosphoric acid, nitric acid, sulfuric acid, hydronic acid, hydrobromic acid, perchloric acid, fluoromatic acid, magic acid (FSO₃HSbF₅), carborane super acid [H(CHB₁₁Cl₁₁)], triflic acid, ethanoic acid, and acetylsalicylic acid. As used herein, a “heavy” acid is an acid having a specific gravity greater than about 1.5. The heavy acid may be present in the amount of from about 1.7% to about 8.6% by weight of the separating composition.

The pH of the separating composition may be greater than 7.5. The pH of the separating composition may also be from about 7.0 to about 8.5. The pH of the separating composition may also be from about 7.6 to about 7.8. The composition may be essentially free of organic solvent. As used herein, the term “organic solvent” refers to solvents that are organic compounds and contain carbon atoms such as, for example, naphtha. In addition to the separating composition, the composition may also comprise hydrocarbon containing materials, such as oil sands, tailings, and the like. The ratio of the separating composition to the hydrocarbon containing materials may be from about 2:3 to about 3:2.

A separating composition may be provided, comprising from about 0.001% to about 2.5% by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics. The separating composition may have a pH of greater than 7.5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8. The wetting agent may be, for example, 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate. The hydrotropic agent may be, for example, MAPHOS® 66H aromatic phosphate ester. The dispersant having flocculating characteristics may be, for example, one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.

The separating composition may further comprise a strong base, which may be, for example, sodium hydroxide. The strong base may be present in the amount of from about 2% to about 9.5% by weight of the separating composition. The separating composition may further comprise a heavy acid, which may be, for example, phosphoric acid. The heavy acid may be present in the amount of from about 1.7% to about 8.6% by weight of the separating composition. The separating composition may also be essentially free of organic solvent.

A separating composition for separating bitumen from oil sands or tailings may be provided, comprising from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:

wherein R¹ is a C₁-C₅ linear or branched alkyl group and n=1 to 8, e.g., an integer between one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate; from about 0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2.0% to about 9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of phosphoric acid. The separating composition may have a pH of from about 7.0 to about 8.5. The separating composition may also be essentially free of organic solvent.

A method for separating bitumen from oil sands may be provided, comprising contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with oil sands comprising bitumen and sand; heating the separating composition and the oil sands; agitating the separating composition and the oil sands; and recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7.5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.

The separating composition used in the exemplary method may be comprised of from about 0.001% to about 2.5% by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.

The separating composition used in the exemplary method may be comprised of from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:

wherein R¹ is a C₁-C₅ linear or branched alkyl group and n=1 to 8, e.g., an integer between one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate; from about 0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to about 9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of phosphoric acid.

With respect to the process conditions under which the method may be carried out, the separating composition and the oil sands may be heated to greater than 25° C.; from about 32° C. to about 72° C.; or from about 54° C. to about 60° C. Any source of heat within the ambit of those skilled in the art may be used.

The ratio of the separating composition to the oil sands may be from about 2:3 to about 3:2. In another embodiment, the ratio of the separating composition to the oil sands may be about 1:1.

The recovered bitumen may be essentially emulsion-free. The exemplary method may be performed without the addition of organic solvent.

In some circumstances, it may prove desirable to subject the separated, recovered bitumen to a second or subsequent aliquot of separating composition. In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh separating composition; heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered bitumen; and recovering the resulting bitumen. Such a “rinse” cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.

The separating composition may be recyclable. Thus, the method may further comprise recovering the separating composition; contacting the recovered separating composition with a second or subsequent aliquot of oil sands comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of oil sands; agitating the recovered separating composition and the second or subsequent aliquot of oil sands; and recovering the bitumen and sand as separate products.

Embodiments may further include a method for processing existing tailings, both to salvage remaining bitumen and to allow for redeposit of the essentially bitumen-free sand. The method may comprise contacting a separating composition comprising a wetting agent, a hydrotropic agent, and a dispersant having flocculating characteristics with tailings comprising bitumen and sand; heating the separating composition and the tailings; agitating the separating composition and the tailings; and recovering the bitumen and sand as separate products. The pH of the separating composition may be greater than 7.5; from about 7.0 to about 8.5; or from about 7.6 to about 7.8.

The separating composition used in the method for processing existing tailings may be comprised of from about 0.001% to about 2.5% by weight of a wetting agent; from about 0.1% to about 4.0% by weight of a hydrotropic agent; and from about 0.25% to about 4.5% by weight of a dispersant having flocculating characteristics.

The separating composition used in the method for processing existing tailings may be comprised of from about 0.001% to about 2.5% by weight of 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate; from about 0.1% to about 4.0% by weight of an aromatic phosphate ester having the formula:

wherein R¹ is a C₁-C₅ linear or branched alkyl group and n=1 to 8, e.g., an integer between one and eight; from about 0% to about 4.5% by weight of sodium pyrophosphate; from about 0% to about 4.5% by weight of tetrapotassium pyrophosphate; from about 2% to about 9.5% by weight of sodium hydroxide; and from about 1.7% to about 8.6% by weight of phosphoric acid.

With respect to the process conditions under which the method for processing existing tailings may be carried out, the separating composition and the tailings may be heated to greater than 25° C.; from about 32° C. to about 72° C.; or from about 54° C. to about 60° C. Any source of heat within the ambit of those skilled in the art may be used.

The ratio of the separating composition to the tailings may be from about 2:3 to about 3:2. In another embodiment, ratio of the separating composition to the tailings may be about 1:1.

The recovered bitumen may be essentially emulsion-free. The method may be performed without the addition of organic solvent.

In some circumstances, it may prove desirable to subject the separated, recovered bitumen from the tailings to a second or subsequent aliquot of separating composition. In such a case, the exemplary method further comprises contacting the separated, recovered bitumen with a second or subsequent aliquot of fresh separating composition; heating the fresh separating composition and the bitumen; agitating the fresh separating composition and the recovered bitumen; and recovering the resulting bitumen. Such a “rinse” cycle may be repeated until the bitumen is essentially free of any sand or other particulate matter.

The separating composition may be recyclable. Thus, the exemplary method for processing existing tailings would further comprise recovering the separating composition; contacting the recovered separating composition with a second or subsequent aliquot of tailings comprising bitumen and sand; heating the recovered separating composition and the second or subsequent aliquot of tailings; agitating the recovered separating composition and the second or subsequent aliquot of tailings; and recovering the bitumen and sand as separate products.

The tar sand slurry is provided through the liquid supply conduit 27 and make up chemistry is supplied through conduit 28. At the junction of the liquid supply conduit 27 and the make up supply conduit 28, the tar sand slurry and liquid/solid mixture in the form of a slurry. Alternatively, other embodiments encompassed by the present invention may include only as single inlet where the fluid/slurry enters the apparatus. This mixture of tar sand slurry is directed into the cylindrical chamber 15 of the housing 12 through the supply conduits 30 and inlet ports 25, as shown. Embodiments may include an inlet port 25 that is provided on either side of the housing 12 in order to equalize the hydraulic pressure on the rotor 17 to prevent undue stress on the bearing assemblies 19. However, this particular configuration is not a limitation of the invention and other configurations of inlet ports may be provided.

An outlet port 35 is provided in the housing 12 and, in some embodiments, is located in the cylindrical wall of the housing to communicate with the cavitation zone 32 in a region of the rotor intermediate or between the arrays of bores 24. Location of the outlet port 35 in this way ensures that the entire volume of the gas/liquid mixture traverses at least one of the arrays of bores 24 and thus moves through a cavitation zone prior to exiting the hydrosonic mixer 11. Further, location of the outlet port 35 within the region of the inner chamber 15 aligned with the void 26 of the rotor prevents cavitation damage that otherwise might occur if the outlet port 35 were aligned with an array of bores 24. An outlet conduit 33 is coupled to the outlet port 35 for receiving treated tar sand slurry and excess air from the hydrosonic mixer 11 and delivering it to a remote location for separation of the excess air from the treated tar sand slurry and subsequent use of the treated tar sand slurry.

In operation, the tar sand slurry is pumped through the liquid supply conduit 27 to the supply conduit 30. Make up chemistry can be supplied through the supply conduit 28 to the stream of tar sand slurry. The tar sand slurry mixture moves through the supply conduits 30 and enters the chamber 15 through supply ports 25 on either side of the rotor 17.

From the supply ports 25, the mixture moves toward the periphery of the rapidly rotating rotor 17 and enters the cavitation zones 32 in the region of the bores 24. Within the cavitation zones 32, millions of microscopic cavitation bubbles are formed in the mixture within and around the rapidly moving bores 24 on the rotor. Since these cavitation bubbles are unstable, they collapse rapidly after their formation. As a result, the millions of microscopic cavitation bubbles continuously form and collapse within and around the bores 24 of the rotor, creating cavitation-induced shock waves that propagate through the mixture in a violent, albeit localized, process.

As the mixture of tar sand slurry the mixture is bombarded by the microscopic cavitation bubbles as they form and further are impacted by the cavitation shock waves created as the cavitation bubbles collapse. This results in a high shear environment that scoures the surface of the sand particles clear of the adhered Bitumen in a manner that does not abrade the equipment surfaces in the same manner as other devices.

After the tar sand slurry has been treated, it flows out of the chamber 15 through the outlet port 35. At this point, Released Bitumen can be separated from the water/sand mixture via a number of simple mechanical separation methods.

Unless specifically stated to the contrary, the numerical parameters set forth in the specification, including the attached claims, are approximations that may vary depending on the desired properties sought to be obtained according to the exemplary embodiments. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

The processes and devices in the above description and drawings illustrate examples of only some of the methods and devices that could be used and produced to achieve the objects, features, and advantages of embodiments described herein. Thus, they are not to be seen as limited by the foregoing description of the embodiments, but only limited by the appended claims. Any claim or feature may be combined with any other claim or feature within the scope of the invention.

The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention. 

1. A method of extracting bitumen from tar sands, the method comprising: providing an apparatus for mixing fluids, the apparatus comprising: a housing defining a substantially cylindrical interior chamber bounded by spaced substantially planar side walls joined by a cylindrical peripheral wall; a substantially cylindrical rotor rotatably mounted within the interior chamber, the rotor having an axis, spaced substantially planar sides, and a cylindrical peripheral surface joining the planar sides; the cylindrical peripheral surface of the rotor and the cylindrical peripheral wall of the chamber defining an annular space therebetween having a substantially uniform dimension in the axial direction of the rotor; at least two arrays of spaced bores formed in the peripheral surface of the rotor, each bore of each array extending radially into the rotor a predetermined distance and opening into the annular space, the each array of spaced bores being arranged in a row that extends around the cylindrical peripheral surface of the rotor and being spaced from other arrays such that a void zone therebetween is created where no bores are formed in the peripheral surface of the rotor; at least one fluid inlet in the housing positioned to introduce fluid into the chamber at predetermined locations adjacent one of the substantially planar sides of the rotor; multiple inlets being substantially aligned to equalize pressure on the rotor as fluid is introduced into the chamber through the fluid inlets; and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber at a third predetermined location adjacent the cylindrical peripheral surface of the rotor, the third predetermined location being aligned within the void zone for withdrawal of fluid after it has passed a row of bores and to minimize cavitation damage at the location of the fluid outlet; and providing a separation composition comprising: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition; a hydrotropic agent; and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.
 2. The method of claim 1, wherein: the hydrotropic agent is present in the amount of from about 0.1% to about 4.0% by weight of the separating composition; and the dispersant having flocculating characteristics is present in the amount of from about 0.25% to about 4.5% by weight of the separating composition.
 3. The method of claim 1, wherein the wetting agent comprises an alkoxylated alcohol surfactant.
 4. The method of claim 1, wherein the wetting agent comprises 2,5,8,11-tetramethyl-6-dodecyn-5,8-diol ethoxylate.
 5. The method of claim 1, wherein the hydrotropic agent comprises a phosphorylated nonionic surfactant.
 6. The method of claim 1, wherein the hydrotropic agent comprises an aromatic phosphate ester having the formula:

wherein R¹ is a C₁-C₅ linear or branched alkyl group, and wherein n=1 to
 8. 7. The method of claim 1, wherein the dispersant having flocculating characteristics comprises a pyrophosphate salt.
 8. The method of claim 1, wherein the dispersant having flocculating characteristics comprises one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.
 9. The method of claim 1, wherein the pH of the separating composition is from about 7.6 to about 8.5.
 10. The method of claim 1, wherein: the separation composition further comprises a strong base; and the strong base is present in the amount of from about 2% to about 9.5% by weight of the separating composition.
 11. The method of claim 1, wherein the separation composition is essentially free of organic solvent.
 12. The method of claim 1, wherein the separation composition further comprises hydrocarbon containing materials, wherein the ratio of the separating composition to the hydrocarbon containing materials is from about 2:3 to about 3:2.
 13. An apparatus for extracting bitumen from tar sands, the apparatus comprising: a housing defining a substantially cylindrical interior chamber bounded by spaced substantially planar side walls joined by a cylindrical peripheral wall; a substantially cylindrical rotor rotatably mounted within the interior chamber, the rotor having an axis, spaced substantially planar sides, and a cylindrical peripheral surface joining the planar sides; the cylindrical peripheral surface of the rotor and the cylindrical peripheral wall of the chamber defining an annular space therebetween having a substantially uniform dimension in the axial direction of the rotor; a first array of spaced bores formed in the peripheral surface of the rotor, each bore of the first array extending radially into the rotor a predetermined distance and opening into the annular space, the first array of spaced bores being arranged in a first row that extends around the cylindrical peripheral surface of the rotor; a second array of spaced bores formed in the peripheral surface of the rotor, each bore of the second array extending radially into the rotor a predetermined distance and opening into the annular space, the second array of spaced bores being arranged in a second row that extends around the cylindrical peripheral surface of the rotor, the first and second rows of bores being spaced apart in the axial direction of the rotor and defining a void zone therebetween such that no bores are formed in the peripheral surface of the rotor; a first fluid inlet in the housing positioned to introduce fluid into the chamber at a first predetermined location adjacent one of the substantially planar sides of the rotor; a second fluid inlet in the housing positioned to introduce fluid into the chamber at a second predetermined location adjacent the other one of the substantially planar sides of the rotor, the second fluid inlet being substantially axially aligned with the first fluid inlet to equalize pressure on the rotor as fluid is introduced into the chamber through the fluid inlets; and a fluid outlet in the housing positioned for withdrawal of fluid from the chamber at a third predetermined location adjacent the cylindrical peripheral surface of the rotor, the third predetermined location being aligned within the void zone for withdrawal of fluid after it has passed a row of bores and to minimize cavitation damage at the location of the fluid outlet, wherein the apparatus is configured to receive a separation composition comprising: a wetting agent in the amount of from about 0.001% to about 2.5% by weight of the separating composition; a hydrotropic agent; and a dispersant having flocculating characteristics, wherein the separating composition has a pH of greater than 7.5.
 14. The apparatus of claim 13, wherein: the hydrotropic agent is present in the amount of from about 0.1% to about 4.0% by weight of the separating composition; and the dispersant having flocculating characteristics is present in the amount of from about 0.25% to about 4.5% by weight of the separating composition.
 15. The apparatus of claim 13, wherein the wetting agent comprises an alkoxylated alcohol surfactant.
 16. The apparatus of claim 13, wherein the hydrotropic agent comprises a phosphorylated nonionic surfactant.
 17. The apparatus of claim 13, wherein the dispersant having flocculating characteristics comprises a pyrophosphate salt.
 18. The apparatus of claim 13, wherein the dispersant having flocculating characteristics comprises one or more of sodium acid pyrophosphate and tetrapotassium pyrophosphate.
 19. The apparatus of claim 13, wherein: the separation composition further comprises a strong base; and the strong base is present in the amount of from about 2% to about 9.5% by weight of the separating composition.
 20. The apparatus of claim 13, wherein the separation composition is essentially free of organic solvent. 